Walchem WBLW100 Series Instruction Manual Download

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Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

TEL: 508-429-1110 WEB: www.walchem.com

WCT/WBLW100 Series

Cooling Tower and Boiler Controller

Instruction Manual

Summary of Contents for WBLW100 Series

Page 1: ... Five Boynton Road Hopping Brook Park Holliston MA 01746 USA TEL 508 429 1110 WEB www walchem com WCT WBLW100 Series Cooling Tower and Boiler Controller Instruction Manual ...

Page 2: ...ponents are expendable and are not covered by any warranty THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EITHER EXPRESS OR IMPLIED AS TO DESCRIP TION QUALITY MERCHANTABILITY FITNESS FOR ANY PARTICULAR PURPOSE OR USE OR ANY OTHER MATTER 180530 Rev Q January 2018 Contents 1 0 INTRODUCTION 1 2 0 SPECIFICATIONS 2 2 1 Measurement Performance 2 2 2 Electrical Input Output 3 2 3 Mechanical 4 2 4 Variabl...

Page 3: ... time Daily Weekly 2 week or 4 week Biocide timers with pre bleed and post add lockout of bleed Intermittent sampling for boilers with proportional blowdown controlling on a trapped sample Time Proportional control Always on unless interlocked Dual set point Probe Wash timer Diagnostic Alarm triggered by High or Low sensor reading No Flow Relay output timeout Sensor error An optional isolated anal...

Page 4: ...lated 600 Ohm max resistive load Resolution 0 0015 of span Accuracy 0 5 of reading Agency Approvals Safety UL 61010 1 2012 3rd Ed CSA C22 2 No 61010 1 2012 3rd Ed IEC 61010 1 2010 3rd Ed EN 61010 1 2010 3rd Ed EMC IEC 61326 1 2012 EN 61326 1 2013 Note For EN61000 4 6 EN61000 4 3 the controller met performance criteria B Class A equipment Equipment suitable for use in establishments other than dome...

Page 5: ...f sensor range High end of sensor range Sample period Time Proportional mode 10 seconds 3600 seconds Sample Time Intermittent Sampling mode 0 seconds 3600 seconds Hold Time Intermittent Sampling mode 0 seconds 3600 seconds Maximum Blowdown Intermittent Sampling mode 0 seconds 3600 seconds Wait Time Intermittent Sampling mode 0 seconds 86 400 seconds Max Rate Pulse Proportional mode 10 pulses minut...

Page 6: ...s 1 Determine the Rate of Steam Production in Pounds per Hour Either read off the boiler name plate water tube boilers or Calculate from horsepower rating fire tube boilers HP x 34 5 lbs hr Example 100 HP 3450 lbs hr 2 Determine the Concentration Ratio BASED ON FEEDWATER A water treatment chemical specialist should determine the desired number of cycles of concentration This is the ratio of TDS in...

Page 7: ... graphs on the next page Use of a flow control valve will give you the best control of the process since the flow rate can be easily adjusted The dial on the valve also gives you a visual indication if the flow rate has been changed If the valve clogs it can be opened to clear the obstruction and closed to the previous position If an orifice plate is used you must install a valve downstream from t...

Page 8: ...inside the controller even when the power switch on the front panel is in the OFF position The front panel must never be opened before power to the controller is REMOVED If your controller is prewired it is supplied with a 8 foot 18 AWG power cord with USA style plug A tool 1 Phillips driver is required to open the front panel 2 When mounting the controller make sure there is clear access to the d...

Page 9: ... Union To Drain To Drain 1 2 3 Figure 4 Typical Boiler Installation Continuous Sampling Install accessories either vertically or horizontally per manufacturer s instructions To Drain Skimmer Blowdown Line 3 4 Min up to Electrode Full Port Block Valve Manual Blowdown Normally Closed Motorized Ball or Solenoid Valve Flow Control Valve or Orifice Union CONDUCTIVITY ELECTRODE TEE 2 ft minimum 1 to 3 f...

Page 10: ...110 VOLT AC OUTLET TO SANITARY SEWER COOLING TOWER OPEN SUMP CIRCULATION PUMP X Unions installed for replacement of solenoid or strainer Y Y strainer Z solenoid TYPICAL INSTALLATION SUBMERSION ELECTRODE OPTION A VALVE X Y Z X VALVE X Y Z X OPTION B TO SANITARY SEWER PROBE NOTE LOCATION OF SOLENOID VALVE USING OPTION A OR OPTION B DEPENDS ON SYSTEM CONFIGURATION DETAIL OF PROBE ASSEMBLY CLIP PROBE ...

Page 11: ...tivity Electrode TEMP WHT TEMP GRN RCV BLK SHIELD XMT RED SAFETY COVER LABEL R SHLD High Pressure Conductivity Electrode GRN WHT RED BLK Condensate Electrode wiring is typical of all three sensor options Figure 8 Contacting Conductivity Sensor Input Wiring 1 2 3 4 5 6 7 8 9 10 11 12 TB2 TB1 FUSE POWER SWITCH POWER SWITCH 1 2 3 4 5 6 7 8 9 10 11 12 R1 R2 R3 N N N N L DIGITAL INPUT OPTIONAL ANALOG O...

Page 12: ... Effect Flow Meter SHIELD INPUT POWER Chart Recorder SIGNAL SHIELD SHIELD R SHLD Figure 10 Digital Input and Analog Output Wiring 1 2 3 4 5 6 7 8 9 10 11 12 TB2 TB1 FUSE POWER SWITCH POWER SWITCH 1 2 3 4 5 6 7 8 9 10 11 12 R1 R2 R3 N N N N L TB3 TB4 TB5 TB6 TB7 pH TB1 ECOND CCOND pH ORP w BNC pH ORP DIS 1 XMT XMT USE FOR INPUT SIGNAL 2 XMT 3 X SHLD 4 5V 5 RCV 6 RCV 7 RCV IN 8 5V 9 TEMP TEMP TEMP T...

Page 13: ...LU 240V BLK 120V BRN 240V Figure 12 W110 AC Power Relay Output Wiring 1 2 3 4 5 6 7 8 9 10 11 12 TB2 TB1 FUSE POWER SWITCH POWER SWITCH 1 2 3 4 5 6 7 8 9 10 11 12 R1 R2 R3 N N N N L TB3 TB4 TB5 TB6 TB7 pH R1 R2 R3 N N N N L TB3 TB4 TB5 TB6 SOLENOID MOTORIZED BALL VALVE PUMP ALARM WHT 120V BLU 240V BLK 120V BRN 240V GRN 120V GRN YEL 240V Power Supply 120 VAC or 240 VAC GRN 120V GRN YEL 240V BLK 120...

Page 14: ...her or Lower keys Once the value of the number is correct use the Enter key to store the new value into memory or use the Cancel key to leave the number at its previous value and go back Changing Names To change the name used to identify an input or output use the Move Cursor key to the character to be changed and change it using either the Make Character Higher or Lower keys Upper case and lower ...

Page 15: ...ighted Press the Enter key Press the Scroll Down key until your language is highlighted Press the Confirm key to change all menus to your language Set date if necessary Press the Scroll Up key until Date is highlighted Press the Enter key Press the Move Cursor key to highlight the Day and then use the Make Character Higher or Lower keys to change the date Press the Confirm key to accept the change...

Page 16: ...tting Setpoint Int Sampling R1 HOA Setting Setpoint Manual R1 HOA Setting Interlock Channels Pulse Prop R1 HOA Setting Setpoint Dual Setpoint R1 HOA Setting Setpoint Probe Wash R1 HOA Setting Input Timer R1 HOA Setting Add Last Missed Only if HVAC mode is enabled Only if model W120 power relay bd installed Additional Settings for On OFF Deadband Duty Cycle Period Duty Cycle Output Time Limit Reset...

Page 17: ...nter key to get to the Details screen Press the Settings key If the name of the relay does not describe the control mode desired press the Scroll Down key until Mode is highlighted Press the Enter key Press the Scroll Down key until the correct control mode is highlighted then press the Confirm key to accept the change This will bring you back to the Details screen Press the Settings key again to ...

Page 18: ...ture compensation Enter the temperature of the buffer and press Confirm Buffer Value only appears for One Point Calibration except when automatic buffer recognition is used Enter the value of the buffer being used Rinse Sensor Remove the sensor from the process rinse it off and place it in the buffer solution or oxidizer free water for Zero Cal or air for the conductivity open air cal Press Confir...

Page 19: ...he next reading shown will consist of an average of 10 of the previous value and 90 of the current value Cable Length The controller automatically compensates for errors in the reading caused by varying the length of the cable Gauge The cable length compensation depends upon the gauge of wire used to extend the cable Cell Constant Do not change unless instructed by the factory The default value is...

Page 20: ...Press the Enter key with an output highlighted to access that output s details and settings NOTE When the output control mode or the input assigned to that output is changed the output reverts to OFF mode Once you have changed all settings to match the new mode or sensor you must put the output into AUTO mode to start control 5 3 1 Relay Any Control Mode Output Details The details for this type of...

Page 21: ...t and a conductivity limit are set the time limit takes precedence The bleed relay will turn off once the time limit is reached or when the prebleed conductivity limit is reached whichever occurs first If the prebleed has a conductivity limit set then the time limit can t be set to zero as this would allow the prebleed to last forever if the conductivity limit is never reached Overlapping biocide ...

Page 22: ...tion from the set point The relay goes through a sequence of activation deactivation as described below The intended purpose of this algorithm is boiler blowdown A sample cannot be supplied to the sensor continuously in many boilers because a recirculating loop is not possible and it would be a waste of hot water to constantly run a sample to a drain A valve is opened intermittently to supply a sa...

Page 23: ...Control Mode Basic Timer Operation When a Probe Wash event triggers the algorithm will activate the relay for the programmed time The relay will activate a pump or valve to supply a cleaning solution to the sensor or sensors The output of the selected sensors will either be held or disabled during the cleaning cycle and for a programmable hold time after the cleaning cycle Special Condition Handli...

Page 24: ... digital flow meter and continuously adjusts the analog 4 20 mA output proportional band to achieve a target PPM level The user enters the target PPM and the data necessary to calculate the proportional band the water flow rate at which the maximum pulse rate will occur required to maintain the target PPM with that flow rate of water output Target PPM x Water Flow Rate liter or gal Cycles x Pump C...

Page 25: ...ntroller see Export User Config file below Press the Enter key and then press the Confirm key to transfer those settings to this controller Export User Config File The User Configuration file contains all settings for the controller Enter this menu to save the controller s settings to a USB stick for using later to restore settings to this controller or to program additional controllers with the s...

Page 26: ...lays have a fuse to protect the controller from devices connected to the relays that draw excessive current Locate the fuse on the circuit board at the back of the controller enclosure underneath the clear cover see figure 7 Gently remove the old fuse from its retaining clip and discard Press the new fuse into the clip replace the clear cover secure the front panel of the controller and return pow...

Page 27: ...sible Cause Corrective Action No flow Check piping for closed valves blockage etc Check recirculation pump Faulty flow switch cable Check with ohmmeter Faulty controller Check by shorting digital input in controller TOTAL ALARM Occurs if the flowmeter totalizer alarm limit is exceeded Possible Cause Corrective Action Normal operation Reset the total to clear alarm AC coupled onto flowmeter cable R...

Page 28: ...rectly Possible Cause Correction Action The software is not functioning If the error message clears on its own no action is required If the error message persists cycle power If the error message still persists return the controller for repair RELAY OR ANALOG OUTPUT CONTROL FAILURE This alarm occurs if software for that output did not run correctly Possible Cause Correction Action The software is ...

Page 29: ...657 Control Board with AO 191613 Ribbon Cable Controller Parts 103875 Panel 102961 Hanger 102586 Nut 190998 03 Switch assembly 3 ft cable 190996 Float 102919 O Ring 191020 03 Switch Float Assembly 3 ft cable 102594 O Ring 102881 Flow Switch Body 190997 03 Flow Switch Assembly 3 ft cable 102917 Nipple 102879 01 Elbow 102387 Sample Valve 102594 O Ring 191646 03 Sensor Graphite or 191647 03 Sensor St...

Page 30: ...e 191638 03 Electrodeless Conductivity sensor CPVC 3 ft cable 102586 Nut 102594 O ring 191020 03 Flow switch assembly 3 ft cable 190997 03 Switch Float assembly 3 ft cable 102594 O ring 102881 Flow switch body 102919 O ring 190998 03 Switch assembly 3 ft cable 190996 Float 191157 Tee assembly 102377 Hanger 103535 Panel 102961 Hanger 103886 Screws 103885 Screws 191683 03 Manifold assembly 3 ft cabl...

Page 31: ... Switch manifold on panel C High pressure contacting conductivity D High pressure contacting cond Flow Switch manifold on panel E Inline submersion 316SS contacting conductivity F 316SS contacting conductivity Flow Switch manifold on panel G Inline submersion electrodeless conductivity H Electrodeless conductivity Flow Switch manifold on panel Sensors WBLW N No sensor A Boiler sensor with ATC 250 ...

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